Sunday, August 25. 2013

As described last week, we had reached the frustrating point
of chasing leaks around the tube ends and a small check list of other minor
issues requiring correction in order to get the boiler fit for the formal hydro
test.

Brian Davies is staying at Union for three weeks to help
with the work and he put in long hours with some of us who were able to spend a
day at Union during the week.Several
important tasks were achieved. With
Jason, he was able to largely complete the cleaning and checking of the air brake
valves.

However the key focus was the boiler.As the number of leaking tubes decreased,
they became more frustrating and more inclined to cause an adjacent tube to
leak when you rolled them.The final
session on Saturday had many of us involved during the day and lasted until 11 at night but by the
end, we were down to one super heater flue that has a small leak around it that
we expect will seal itself when the boiler is fully heated, although it drips
very slowly under hydro pressure.

Brian and Jason examine for tiny leaks

Then carefully fix what you have
found!

So, Brian, Jim and I were back in the shop at 8:30 on Sunday,
unfortunately not to assist with the last day of Thomas but to meet with the
FRA inspector for the formal hydro test.I am glad to say that the old lady passed !.Aside from the tube end and a few drips from
tri-cocks and blow down valves she held pressure very well with no sign of
leakage.

So Saturday was rather a frustrating day.Very little on 1630, aside from the tubes,
could be worked on until the hydro was completed.

Cameron and Phil worked with Tom on the bolster for the
Shay.

Cameron and Phil set up to machine the
bolster

Richard and Ed continued to work on preparing the cladding
for lagging in the cab.

Bob finally received a suitable breaker to link the planer
into the supply panel.So he was able to
continue work on running power to the planer.

However on Sunday, after the test, a great deal of work
opened up.

The tubes can now be beaded so, in preparation for that, I
spent quite a while in the smokebox grinding tube ends to the exact 1/4 inch
required to formgood bead.Later Brian took over and, by the time that I
left, we were close to the point where he can bead all flues and tubes in the
smokebox that are to be beaded.Ideally
we want to get this done in the next couple of days so that the beaded tubes
can be tested for leaks by Wednesday.

On Wednesday we hope to take off the dome cover, drain the
boiler and start drying it out so that the inspector can carry out the internal
inspection on Friday.This is a Federal
requirement.When a boiler has been over
pressured, as it is for the formal hydro test, it must be inspected to ensure
that nothing internal, such as the brace attachments, has been damaged or
loosened.After this, any pressure
testing is strictly limited to boiler pressure (180 psi).If any pressure beyond this is applied a
further internal inspection is required.

Beading of the smokebox end is essential before a lot of
work starting with refitting the super heater elements and then moving on to the
rest of the smokebox equipment can be undertaken.

In the cab, work will now start on lagging the firebox and
fitting the cladding so that all the controls can be finally refitted.With the hydro complete, we can now start
covering the boiler again.Up until
today, none of this could be started as a clear view of all the surfaces of the
boiler was required for the inspection.

In the firebox, Jerry applied the protective paint to the
patch and rivets below where the grates will fit.Once this is dry, the grates that have been
removed while we worked on the patch, will be refitted.

One key thing about the milestone today is that, while she
may currently look less complete than she did in 2011, we have actually passed
the key inspection step for which we were preparing in Spring 2011 when we hit
the problem with the firebox.

So overall a very successful week.While not too much visible has changed, but we
have removed the barrier to a whole lot of tasks that will make 1630 look much
more like an operating locomotive again in the next month.

Andrew,
Yes. A lot of us are also very keen to see her run!.
Just to avoid any excessive expectations. I really do not expect her to be in any normal service this year. She may look untidy and incomplete (lagging and painting for example). Key will be do do some running in and testing so that we know any work needed to ensure full availability for 2014.
Nigel

Congratulations to you and the whole Steam Team at IRM! 1630 passing the Hydro Test is a real milestone only achieved through alot of difficult and dirty work. Maybe now pace quickens and the finish line is in sight. Good Job! Ray

Thank you for the time and effort put into the ongoing blog updates. I have been following them for some time. Between the detailed description of the work completed and photos my knowledge of steam locomotives and what it takes to maintain and operate them is greatly increased.

I saw the rear of 1630's tender today (9-2-13) while I was on the green hornet street car leaving barn 9, and I was VERY happy to see a glance of it after last seeing it for a freight photo run-by in '04. I'm so happy to hear that she is getting closer to returning! Keep up the good work!
Jack

My grandparents used to take me every summer to watch and ride the 1630. In 20004 was the last time I saw it ran with my new born daughter. I saw it get put away. I follow up on the results of the! 1630. Do you think it will be up and running next year? For me that is the hi lite of the museum. Brings back a lot of awesome memories.

Andrew,
Our whole focus is that 1630 should be running routinely next year.
I would never make myself or the museum hostage to fate by promising at this stage that she will be in normal service. The risks of an unexpected problem are always there when you deal with 100 year old steam locomotives.
However, a lot of us have devoted a great deal of our spare time to ensuring that she will be running and will be at least as disappointed as you should anything prevent this.
Nigel

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Comments

Nigel Bennett about Steam Department Update June 2015Wed, 07-29-2015 07:42Subject to the general caveat that
a 100 year old steam engine can
always develop a last minute fault,
it is planned that #1630 will
operate 8/1 and [...]

CincyCubfan23 about Steam Department Update June 2015Wed, 07-29-2015 06:28Nigel - First, THANK YOU for all
the work you do (and everyone else
at IRM, for that matter)!
I believe I know the answer, but
I'll ask anyhow. [...]

Nathan about Steam Department Update June 2015Mon, 07-27-2015 16:26Nigel,
All matters of practicality do
indeed have to be taken into
consideration.
That said, as another suggestion,
you may want to talk to your [...]

Nigel Bennett about Steam Department Update June 2015Mon, 07-27-2015 07:38Nathan,
All ideas to be considered and
depends on how this year turns
out.
The big reason we run Thomas over
the route we do is the space [...]

Nathan about Steam Department Update June 2015Sun, 07-26-2015 19:24Hi Nigel,
Just noticed the comments and plans
for Thomas on this thread and am
intrigued.
It seems like a great idea to have
#1630 push the Percy [...]

Nigel Bennett about Steam Department Update June 2015Sun, 07-26-2015 09:41Andrew,
No. The Thomas train will follow
its normal route.
There will be two event trains, the
Thomas train and the Percy train
(standard DOWT [...]

Nigel Bennett about Steam Department Update June 2015Sat, 07-25-2015 08:45Peter,
The Thomas days will be
significantly different this year.
There will be a Percy train as well
as a Thomas train and, subject to
the [...]

Peter D. about Steam Department Update June 2015Fri, 07-24-2015 23:51Greetings: Quick question regarding
steam operations...In addition to
Thomas, when would you expect a
steam locomotive to be on the
tacks. Thanks.